Materials and Properties for Cold Spray Part

Manufacture
28/05/15
Some Guys From Spee3d

• CEO
– Byron
Kennedy

SPEE3D 2
Some Guys From Spee3d

• CEO
– Byron
Kennedy

• CTO
– Steve
Camilleri

SPEE3D 3
Some Guys From Spee3d

• CEO
– Byron
Kennedy

• CTO
– Steve
Camilleri

• Senior
Metallurgist

SPEE3D 4
Some Guys From Spee3d

• CEO
– Byron
Kennedy

• CTO
– Steve
Camilleri

• Senior
Metallurgist

SPEE3D 5
Some Guys From Spee3d

• CEO
– Byron
Kennedy

• CTO
– Steve
Camilleri

• Senior
Metallurgist

SPEE3D 6
Some Guys From Spee3d

• CEO
– Byron
Kennedy

• CTO
– Steve
Camilleri

• Senior
Metallurgist

US VP/GM
– Bruce
Colter

SPEE3D 7
LIGHTSPEE3D

SPEE3D 8
WARPSPEE3D

SPEE3D 9
SPEE3D 10
Nozzle
Cover

SPEE3D 11
Unnecessarily
Strong Nozzle
Cover
Nozzle Cover

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Unnecessarily
Strong Nozzle
Cover
Nozzle Cover

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Unnecessarily
Strong Nozzle
Cover
Nozzle Cover

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Unnecessarily
Strong Nozzle
Cover
Nozzle Cover

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Logos

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Logos

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SPEE3D 18
Rocket Nozzle Ablative Cooling Liner

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Rocket Nozzle Ablative Cooling Liner Thing

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Rocket Nozzle Ablative Cooling Liner Thing

SPEE3D 21
Cold Spray AM – The Flow Chart

POWDER GEOMETRY

DIGITAL PROCESS
SHAPE

PROPERTIES
SERVICES

SPEE3D 22
The Process: Three Critical Subsystems

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SPEE3D – Three Critical Subsystems

Classic Cold Spray

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SPEE3D – Three Critical Subsystems

Classic Cold Spray

Toolpathing System

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SPEE3D – Three Critical Subsystems

Classic Cold Spray

Toolpathing System

Heat Treatment

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High
Initial Condition: Complex

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High
Initial Condition: Complex
Part Constraints:
• Large
• Elaborate
• Multiple materials
• Coated
• QA History

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Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High
Value of Part: Low - Med
Initial Condition: Complex
Part Constraints:
• Large
• Elaborate
• Multiple materials
• Coated
• QA History

SPEE3D 34
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High
Value of Part: Low - Med
Initial Condition: Complex
Initial Condition: Flat Plate
Part Constraints:
• Large
• Elaborate
• Multiple materials
• Coated
• QA History

SPEE3D 35
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High
Value of Part: Low - Med
Initial Condition: Complex
Initial Condition: Flat Plate
Part Constraints: Part Constraints:
• Large
• Single Material
• Elaborate
• Thick-walled Structure
• Multiple materials
• No pre-existing QA
• Coated
• QA History

SPEE3D 36
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High
Value of Part: Low - Med
Initial Condition: Complex
Initial Condition: Flat Plate
Part Constraints: Part Constraints:
• Large
• Single Material
• Elaborate
• Thick-walled Structure
• Multiple materials
• No pre-existing QA
• Coated
• QA History
Implications:
• Suits having Operator
• Heat Treatment is highly constrained
• As-Sprayed must hit Properties

SPEE3D 37
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High

m
Value of Part: Low - Med
Initial Condition: Complex

il u
Initial Condition: Flat Plate
Part Constraints: Part Constraints:

• H e
• Large
• Elaborate
Multiple materials
• Single Material
• Thick-walled Structure
• No pre-existing QA
• Coated
• QA History
Implications:
• Suits having Operator
• Heat Treatment is highly constrained
• As-Sprayed must hit Properties

SPEE3D 38
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High

m
Value of Part: Low - Med
Initial Condition: Complex

il u
Initial Condition: Flat Plate
Part Constraints: Part Constraints:

• H e
• Large
• Elaborate
Multiple materials
• Single Material
• Thick-walled Structure
• No pre-existing QA
• Coated
Implications:
• QA History
• Makes sense to automate
Implications:
• Cost constrained
• Suits having Operator
• Heat Treatment is highly constrained
• As-Sprayed must hit Properties

SPEE3D 39
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High

m
Value of Part: Low - Med
Initial Condition: Complex

il u r
Initial Condition: Flat Plate
Part Constraints:

e
• Large i
Part Constraints:

A
• Single Material

H
• Elaborate
• Thick-walled Structure
• Multiple materials
• No pre-existing QA
• Coated
Implications:
• QA History
• Makes sense to automate
Implications:
• Cost constrained
• Suits having Operator
• Heat Treatment is highly constrained
• As-Sprayed must hit Properties

SPEE3D 40
Comparison: Repair and Additive Cold Spray

REPAIR COLD SPRAY ADDITIVE COLD SPRAY

Value of Part: High

m
Value of Part: Low - Med
Initial Condition: Complex

il u r
Initial Condition: Flat Plate
Part Constraints:

e
• Large i
Part Constraints:

A
• Single Material

H
• Elaborate
• Thick-walled Structure
• Multiple materials
• No pre-existing QA
• Coated
Implications:
• QA History
• Makes sense to automate
Implications:
• Cost constrained
• Suits having Operator
• Heat Treatment is highly constrained • Performance deficit
• As-Sprayed must hit Properties

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Heat Treatment of Cold Spray AM

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Heat Treatment of Cold Spray AM

SPEE3D 43
Heat Treatment of Cold Spray - Precedents

SR = 176C x 1hr
T6 = 176C x 8hr

Young, Sparber 2017

Rokni, Widener et al 2017

SPEE3D 44
Thermal Relaxation of “Adhesive” bond into a “Metallurgical” bond

SPEE3D 45
Improvement in Bond Performance – Why?

• Jay Krusic and Halsey

Oostergard UNSW
• Solid Mechanics still
applies
• Treat IPB as continuum
• Annealing softens SPD
Zone

SPEE3D 46
Improvement in Bond Performance – Why?

• Jay Krusic and Halsey

Oostergard UNSW
• Solid Mechanics still
applies
• Treat IPB as continuum
• Annealing softens SPD
Zone

Michael Leunig
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SPEE3D 48
THEM

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Advanced Manufacturing Alliance

THEM

US

SPEE3D 50
SPEE3D 51
SPEE3D 52
SPEE3D 53
Materials Packages

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Materials Packages

AlPHA1: General Purpose Structural Aluminium

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Materials Packages

AlPHA1: General Purpose Structural Aluminium

Kappa2: General Purpose Structural Bronze

SPEE3D 56
Materials Packages

AlPHA1: General Purpose Structural Aluminium

Kappa2: General Purpose Structural Bronze

Kappa3: Conductive Copper

SPEE3D 57
 AlPHA1 “Aluminium, Precipitation Hardened”
Mechanicals: Meet Cast 356 Spec

Applications: Covers, Housings, Moulds, Fixtures,

Heat Sinks, “Cast”, “Low Stress/Stiffness Limited”

Powder: 6061 Chemistry, D50 = 34-45um

Heat Treatment: Modified T6

Average Minimum Standard Deviation

Sample
Spec Axis
Size Hrdns Elongtn YS UTS Elongtn YS UTS Elongtn YS UTS

HRB MPa
% MPa MPa % MPa MPa % MPa
SPEE3D 15 X 5.2 190 241 4.0 183 235 0.5 3 3
44
AlPHA1 5 Z 4.8 180 235 3.0 175 222 N/A N/A N/A

356 3.0 207

SPEE3D 58
 AlPHA1 “Aluminium, Precipitation Hardened”
Mechanicals: Meet Cast 356 Spec

Applications: Covers, Housings, Moulds, Fixtures,

Heat Sinks, “Cast”, “Low Stress/Stiffness Limited”

Powder: 6061 Chemistry, D50 = 34-45um

Heat Treatment: Modified T6

Elastic Modulus: 62GPa

Conductivity: 36±2% IACS

Fatigue, R=0.2: >2.8 x 106 cycles @ 100 MPa

>2.1 x 105 cycles @ 135 MPa

SPEE3D 59
AlPHA1 - Heat Treatment

Three Stage Heat

Treatment:

Sinter: 610C x 5hr + AC/FC

Solutionise: 530C x 1hr +

WQ/AqPol

Age: 160C x 4hr + AC

SPEE3D 60
Kappa2 – General Purpose Structural Bronze

Mechanicals: UTS = >270MPa, >3.6%

Applications: Machine elements, marine

housings/fixtures, pump components

Chemistry: “Unhardenable” Aluminium Bronze

Powder: -325#

Heat Treatment: Homogenise

Averages Minima

Spec Sample Size Axis

Elongtn YS UTS Elongtn YS UTS

% MPa MPa % MPa MPa

SPEE3D Alpha1 5 X 4.4 197 279 3.6 188 272

SPEE3D 61
Kappa2 - Heat Treatment

Homogenise: 950C x 14hr + FAC

SPEE3D 62
Kappa3 – Conductivity Applications

Conductivity: >88% IACS

Applications: Moulds, Busbars, Cable clamps,

heat sinks

Chemistry: Cu, 99.7%

Powder: Cu -325#

Heat Treatment: Anneal

Averages Minima

Spec Sample Size Axis

Elongtn YS UTS Elongtn YS UTS

% MPa MPa % MPa MPa

SPEE3D Kappa3 5 X 4.4 197 279 3.6 188 272

SPEE3D 63
Kappa3 - Heat Treatment

Anneal: 400C x 4hr

SPEE3D 64
THANK YOU
SPEE3D 65
Heat Treatment of Cold Spray - Precedents

SR = 176C x 1hr
T6 = 176C x 8hr

Rokni, Widener et al 2017

SPEE3D 66
Improvement in Fracture Performance – Why?

• Fracture between particles

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Improvement in Fracture Performance – Why?

• Fracture between particles

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Improvement in Bond Performance – Why?

• Fracture between particles

• Improvement is improvement in bond
performance

SPEE3D 69
Improvement in Bond Performance – Why?

• Fracture between particles

• Improvement is improvement in bond
performance
• Sintering?

SPEE3D 70
Improvement in Bond Performance – Why?

• Two theories:

– “Sintering” -Relaxation of adhesive

bond

– Linear Elastic Fracture Mech

SPEE3D 71
Improvement in Bond Performance – Why?

“Adhesive bond” thermally relaxes to

become “metallurgical” bond

SPEE3D 72
Improvement in Bond Performance – Why?

“Adhesive bond” thermally relaxes to

become “metallurgical” bond

SPEE3D 73
Thermal Relaxation of “Adhesive” bond into a “Metallurgical” bond

SPEE3D 74
Improvement in Fracture Toughness

• Jay Krusic and Halsey

Oostergard UNSW

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Improvement in Bond Performance – Why?

• Jay Krusic and Halsey

Oostergard UNSW

SPEE3D 76
Improvement in Bond Performance – Why?

• Jay Krusic and Halsey

Oostergard UNSW
• Solid Mechanics still
applies
• Treat IPB as continuum

SPEE3D 77
Improvement in Bond Performance – Why?

• Jay Krusic and Halsey

Oostergard UNSW
• Solid Mechanics still
applies
• Treat IPB as continuum
• Annealing softens SPD
Zone

SPEE3D 78
Improvement in Bond Performance – Why?

• Jay Krusic and Halsey

Oostergard UNSW
• Solid Mechanics still
applies
• Treat IPB as continuum
• Annealing softens SPD
Zone

Michael Leunig
SPEE3D 79
SPEE3D 80
SPEE3D 81
If something is good, more must be better

SPEE3D 82
SPD Zone Hardness – Refractory?

Rokni, Widener et al 2015

• Segregation of Si and Mg to
SPD Zones

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SPD Zone Hardness – Refractory?

Rokni, Widener et al 2015

• Segregation of Si and Mg to
SPD Zones
• Some recovery in SPD zones
at 450C

SPEE3D 84
SPD Zone Hardness – Refractory?

Rokni, Widener et al 2015

• Segregation of Si and Mg to
SPD Zones
• Some recovery in SPD zones
at 450C

Mutual stabilisation of solute

segregation and xtallographic
defects

SPEE3D 85
SPD Zone Hardness – Refractory?

Rokni, Widener et al 2015

• Segregation of Si and Mg to
SPD Zones
• Some recovery in SPD zones
at 450C

Mutual stabilisation of solute

segregation and xtallographic
defects

SPEE3D 86
Onwards, to Higher Temperature

• Experiment with High Temp

“Homogenisation” Treatments

SPEE3D 87
Onwards, to Higher Temperature

Experiment with High Temp

“Homogenisation” Treatments
– 530C – 620C + Solutionise +
Age

SPEE3D 88
Onwards, to Higher Temperature

• Experiment with High Temp

“Homogenisation” Treatments
– 530C – 620C + Solutionise + Age

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Onwards, to Higher Temperature

• Metallurgical trend + “UTS Plateau” – Still Weird

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UTS Plateau – Why?

Rokni et al 2017

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UTS Plateau – Why?

Rokni et al 2017 – Duplex, not a continuum

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UTS Plateau – Why?

Rokni et al 2017 – Duplex, not a continuum

Harder = Higher Yield Stress

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UTS Plateau – Why?

Rokni et al 2017 – Duplex, not a continuum

Harder = Higher Yield Stress CORE YIELDS BEFORE SPD ZONE

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UTS Plateau – Selective Yielding

• Idealised Duplex – Core, SPD

and IPB

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UTS Plateau – Selective Yielding

• Idealised Duplex – Core, SPD

and IPB

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UTS Plateau – Selective Yielding

• Idealised Duplex – Core, SPD

and IPB

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UTS Plateau – Selective Yielding

• Idealised Duplex – Core, SPD

and IPB

SPEE3D 98
UTS Plateau – Selective Yielding

• Idealised Duplex – Core, SPD

and IPB

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UTS Plateau – Selective Yielding

• Idealised Duplex – Core, SPD

and IPB

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Bond Strength, Not Matrix Strength is Decisive

SPEE3D 101
Bond Strength, Not Matrix Strength is Decisive

SPRAYING STRONGER
MATERIALS DOES NOT MAKE
STONGER COLD SPRAY!!

SPEE3D 102
7075 . . . . Nooooooo. . . .

SPEE3D 103
7075 . . . . Nooooooo. . . .

Story, Brewer, Heat Treamtent of Gas Atomised Powders for

CS Deposition

SPEE3D 104
7075 . . . . Nooooooo. . . .

140MPa

Story, Brewer, Heat Treamtent of Gas Atomised Powders for

CS Deposition

SPEE3D 105
7075 . . . . Nooooooo. . . .

97MPa
140MPa

Story, Brewer, Heat Treamtent of Gas Atomised Powders for

CS Deposition

SPEE3D 106
7075 . . . . Nooooooo. . . .

83MPa

97MPa
140MPa

Story, Brewer, Heat Treamtent of Gas Atomised Powders for

CS Deposition

SPEE3D 107
All else equal,

SPEE3D 108
All else equal,

for a given level of nozzle

energy below saturation,

SPEE3D 109
All else equal,

for a given level of nozzle

energy below saturation,

a softer material will be

stronger than a harder
material.

SPEE3D 110
All else equal,

for a given level of nozzle

energy below saturation,

a softer material will be

stronger than a harder
material.

SPEE3D 111